Panel wall structure for use in a tower/frame structure and cooling tower

ABSTRACT

A double wall panel member for use in a panel wall is provided which includes a tongue-configured end and a groove-configured end. The panel member includes a first outer wall spaced laterally from a second outer wall, and the groove-configured end has a first groove wall portion extending from the first outer wall and a second groove wall portion extending from the second outer wall, where the first groove wall portion extends further outward than the second groove wall portion. When connected, the wall panel members are assembled with the groove end pointing or oriented upward (not downward) and the tongue end pointing or oriented downward (not upward).

CROSS-REFERENCE TO RELATED APPLICATION(S) AND CLAIM OF PRIORITY

The present application hereby claims priority under 35 U.S.C. §119(e)to U.S. Provisional Patent Application No. 62/300,554 filed on Feb. 26,2016.

TECHNICAL FIELD

The present invention relates to a panel wall structure for atower/frame structure and a cooling tower and components for buildingsame.

BACKGROUND

The configuration of the prior art wall panel members and theinterconnections they form when assembled have been found to bedeficient—allowing water (or other liquids) to leak from interior toexterior of the cooling tower. During installation, conventional priorart wall panel sections are stacked one on top of each other, and thejoints are caulked. This prior art connection mechanism is aconventional tongue and groove type connection, with the groove pointingdownward and the tongue pointing upward.

Water leaking thru the wall to the exterior has several drawbacks,mainly the undesirable evaporation of the cooling water, as well ascreating discoloration of the exterior wall. Accordingly, there exists aneed for a new double wall panel structure and interconnections betweenmultiple panels which minimize water or other liquids from leakingthrough the joints.

SUMMARY

In accordance with one embodiment, there is provided a double wall panelmember or structure for use in a wall within a cooling tower. The panelwall member includes a double wall panel member having a first outerwall spaced laterally from a second outer wall, the first and secondouter walls comprising fiber reinforced material; a first end having atongue-type portion extending from the first and second outer walls andhaving a width narrower than a width of the double wall panel member;and a second end having a groove-type portion and having a first groovewall portion extending from the first outer wall and a second groovewall portion extending from the second outer wall, the first groove wallportion extending further outward than the second groove wall portion.

In accordance with another embodiment, there is provided a panel wallfor use with a cooling tower. The panel wall includes a first doublewall panel member and a second double wall panel member. Each doublewall panel member further includes a first outer wall spaced laterallyfrom a second outer wall, the first and second outer walls comprisingfiber reinforced material, a first end having a tongue-type portionextending from the first and second outer walls and having a widthnarrower than a width of the double wall panel member, and a second endhaving a groove-type portion and having a first groove wall portionextending from the first outer wall and a second groove wall portionextending from the second outer wall, the first groove wall portionextending further outward than the second groove wall portion. The firstend and the second end of the first double wall panel are interconnectedto the second end and the first end, respectively, of the second doublewall panel.

In accordance with another embodiment, there is provided a cooling towerhaving a support frame structure defining an interior volume and havingat least a first column and a second column; a fluid distribution systemto distribute fluid within the interior volume defined by the supportframe structure; a heat transfer material within the interior volumedefined by the support frame structure and for receiving fluid from thefluid distribution system and through which the fluid travels; a fluidcollection basin disposed beneath the support frame structure; airmoving equipment operable for causing air movement for heat transferbetween the fluid and air; and an exterior panel wall coupled to andspanning between the first column and the second column. The exteriorpanel wall includes a first double wall panel member and a second doublewall panel member. Each double wall panel member has a first outer wallspaced laterally from a second outer wall, a first end having atongue-type portion extending from the first and second outer walls andhaving a width narrower than a width of the double wall panel member,and a second end having a groove-type portion and having a first groovewall portion extending from the first outer wall and a second groovewall portion extending from the second outer wall, the first groove wallportion extending further outward than the second groove wall portion.The first end and the second end of the first double wall panel areinterconnected to the second end and the first end, respectively, of thesecond double wall panel, and the second ends are oriented upward andthe first ends are oriented downward.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, and theadvantages thereof, reference is now made to the following descriptionstaken in conjunction with the accompanying drawings, wherein likenumbers designate like objects, and in which:

FIG. 1A illustrates a perspective and partial cross-sectional view of aprior art double wall panel member;

FIG. 1B illustrates a cross-sectional view of a prior art wall panelstructure formed using two of the prior art wall panel members shown inFIG. 1A;

FIG. 1C illustrates in more detail a cross-sectional view of theinterconnection between the two prior art wall panel members shown inFIG. 1B;

FIGS. 2A and 2B are cross-sectional and perspective views of a wallpanel member in accordance with the present disclosure;

FIG. 3 is a more detailed cross-sectional view with dimensionalinformation of the wall panel member shown in FIGS. 2A, 2B in accordancewith one embodiment;

FIG. 4 illustrates in more detail a cross-sectional view of aninterconnection between two wall panel members shown in FIGS. 2A, 2B and3;

FIGS. 5A and 5B illustrate two views of a wall panel structure formed ofmultiple wall panel members for use as an exterior wall in a coolingtower;

FIGS. 6A, 6B and 6C illustrate various views of a cooling towerincorporating the wall panel structure having multiple wall panelmembers in accordance with the present disclosure; and

FIGS. 7A, 7B and 8A, 8B are detailed cross-sectional views withdimensional information of alternative wall panel members in accordancewith other embodiments.

DETAILED DESCRIPTION

Now referring to FIGS. 6A, 6B, and 6C, there is illustrated variousviews of a cooling tower 600 in accordance with the present disclosure(and which incorporates a number of the wall panel members described inFIGS. 2A-2B, 3 and 4 and herein). It will be understood that the coolingtower 600 and the structures shown throughout the remainder of thefigures and described herein represent examples, and the presentdisclosure is not limited to the structures shown and described.

A cooling tower, generally designated by reference numeral 600 is shownwith two cells 632. Each cell 632 is shown as a square about forty-twofeet on each side, so its overall footprint is about forty-two byeighty-four feet. Each cell 632 is shown with nine (3×3) bays, with eachbay about fourteen by fourteen feet. Other configurations arecontemplated, including a single cell or multiple cells, with each cellhaving any number of bays (e.g., 2×2, 3×3, or uneven combinations). Eachcell 632 includes a fan 634 held within a fan shroud 636 that maygenerally be formed of a fiber reinforced plastic structure that isassembled on top of the cooling tower 600. The fan 634 sits atop ageared fan-speed reducer which itself receives a drive shaft extendingfrom a fan motor. The fan, fan speed reducer and motor may be mounted asconventional in the art, as for example, mounting on a beam such as asteel tube or pipe of appropriately chosen structural characteristicssuch as bending and shear strength and torsion resistance, or theequipment may be mounted on a beam or joist constructed offiber-reinforced plastic (FRP). The motor and beam may be located on theroof or top of the cooling tower 600 or within it. In the illustratedembodiment, the fan shroud 636 is mounted on top of a flat deck 638 ontop of the cooling tower 600 with a guard rail 640 around the perimeter.A ladder 641 or stairway 643 may also be provided for access to thedeck, and walkways may also be provided on the deck.

Beneath the deck 638 are the upper levels 642 (122 in FIG. 1A) of thecooling tower 600 and beneath the upper levels 642 is the bottom or airintake level 644 (120 in FIG. 1A). Beneath the air intake level 644 is ameans or mechanism for collecting cooled water from the fill system. Inthe illustrated embodiment, the collecting means or mechanism is a basin646, into which cooled water drips and is collected.

The exterior of the upper levels 642 include a casing or panel wallstructure 648 that directs the entry of air into the lower levels—so airpasses below and upward through the fill material. The panel wallstructure 648 is novel and designed to reduce or eliminate water leakingfrom the interior to the exterior of the cooling tower. The novel panelwall structure in accordance with the present disclosure will bedescribed in further detail below.

As shown in FIG. 6C, the upper levels 642 include a fill level 650 andwater distribution level 652. The fill level 650 is below the waterdistribution level 652, so that water is distributed to drip through thefill level 650 to the collecting basin 646 below. Air is moved throughthe fill level 650 past the water to cool it. The illustrated fan 634comprises one possible means for causing air to move through the fillsystem, although other means or mechanisms may b used, such as a blowern a cross-flow arrangement.

As known in the art, the fill level 650 is filled with fill material 654that provides a heat transfer function and media. Generally, the fill isopen-celled material that allows water to pass downwardly and air topass upwardly, with heat transfer taking place between the water and airas they pass. Open-celled clay tile or polyvinyl chloride materials orother open cell heat transfer media may be used. Various types of fillmaterial may be used, and such fill material is commercially available.The cooling tower 600 of the present invention is not limited to use ofany particular type of fill material. The present invention is alsoapplicable to cross-flow designs.

A water distribution system 649 in the water distribution level 652above the fill level 650 includes a distribution header 656 thatreceives hot water from a supply pipe (not shown) that may be connectedto the inlet 658 on the exterior of the cooling tower. One distributionheader 656 extends across the width of each cell, and each is connectedto a plurality of lateral distribution pipes 660 extendingperpendicularly from the header 656 to the opposite edges of each cell.The lateral distribution pipes 660 are spaced evenly across each bay,with lateral distribution pipes being provided in each of the fourteenby fourteen foot bays of the illustrated embodiment. Larger or smallerbays may be provided with an appropriate number and spacing of waterdistribution pipes provided.

Each lateral distribution pipe 660 has a plurality of downwardlydirected spray nozzles 663 connected to receive hot water and spray itdownward in drops onto the fill material 654, where heat exchange occursas gravity draws the water drops down to the basin and the fan drawscool air up through the cooling tower. Each lateral distribution pipemay have, for example, ten nozzles, so there may exist eighty nozzles ineach bay 662. The water distribution system 649 is shown and describedfor purposes of illustration only and other designs may also beutilized.

The cooling tower 600 also has a tower/frame structure 100 to supportthe fan system, water distribution system and fill material, etc., whichmay be constructed as desired. One example of a tower/frame structurethat may be utilized in the cooling tower is described in U.S. Pat. No.7,275,734 (including FIGS. 1-5 and the accompanying textual descriptiontherein), which is incorporated herein by reference.

The tower structure 100 defines an interior volume 665 within which thefill material and substantial portion of the water distribution systemare contained. The frame or structure 100 includes a plurality ofvertical columns and horizontal beams, and other components.

The cooling tower 600 further includes the collecting basin 646 thatdefines a base 691 on which the vertical columns 112 are mounted throughfootings 686. The types of footings and connections available aregenerally known to those in the art.

As such, the frame/structure 100 includes a plurality of interconnectedcolumns, beams and joists that provide a supporting structure foradditional or other components that may be included in the cooling tower600. Additional components and/or more detailed descriptions of thesecomponents in the cooling tower 600 are described in U.S. Pat. No.5,902,522, which is incorporated herein by reference.

Now referring to FIG. 1A, there is illustrated a prior art wall panelsection or member 10 having a double wall design. These sections 10 areconnected together to form a prior art exterior panel wall 20 (similarto structure 648 shown in FIG. 6). For illustration purposes only, FIG.1B illustrates the wall 20 with two sections 10 interconnected together.The sections 10 may be constructed or formed with different dimensions(e.g., length, height and thickness). A typical section 10 may be on theorder of 2 to 4 feet in height, 8 to 30 feet in length, and 1-3 inchesin thickness—depending on the pultrusion process utilized to manufacturethe wall panel sections 10. Referring to FIG. 1C, there is illustratedin more detail a cross-sectional view showing an interconnection betweenthe two prior art wall panel sections 10 shown in FIG. 1B. Though notshown in FIGS. 1A-1C, a typical prior art exterior wall panel 20 will beconstructed with a number of individual wall panel sections 10. Thenumber depending on the overall desired dimension of the wall 20.

The configuration of the prior art wall panel members and theinterconnections they form when assembled have been found to bedeficient—allowing water to leak from interior to exterior of thecooling tower. During installation, each wall panel section 10 isstacked one on top of each other, and the joints are caulked. This priorart connection is a tongue and groove type connection, with the groovepointing downward and the tongue pointing upward.

Water leaking thru the wall to the exterior has several drawbacks,mainly the undesirable evaporation of the cooling water, as well ascreating discoloration of the exterior wall.

Now referring to FIGS. 2A and 2B, there are shown cross-sectional andperspective views of a new wall panel member 200 in accordance with thepresent disclosure. The wall panel member includes a first wall 202 anda second wall 204, with the walls 202, 204 spaced laterally from eachother. The thickness may range from about ½ inch to about 4 inches, andother embodiments ranges from 1-2 inches, or is about 1¼ inch. Each wall202, 204 has an outer surface and an inner surface. One or more innerwalls 206 interconnect the first wall 202 and the second wall 204, asshown, to couple the walls 202, 204 together. The ends are configured tointerconnect to provide a mechanism to couple two panels 200 together toform the panel wall structure 648 (as shown in FIG. 6C).

The dimensions of the wall panel member 200 may be chosen as desired.FIG. 3 illustrates, in one embodiment, the wall panel member 200 havingcertain dimensions. Other dimensions are possible. Similar to the priorart wall panel 100, the wall panel members 200 when assembled form atongue and groove type connection. However, in distinct contrast withthe prior art wall panel members, the wall panel members 200 areassembled with the groove end 210 pointing or oriented upward (notdownward) and the tongue end 212 pointing or oriented downward (notupward). The specific configurations of the groove end 210 and thetongue end 212 are also shown in FIG. 3.

FIG. 4 illustrates in more detail a cross-sectional view showing aninterconnection between two wall panel members 200, in accordance withthe present disclosure. It will be appreciated that the groove end 210includes two extending walls (or flanges) 230, 232 of unequal lengths—asshown. The extending wall 230 extends from the wall 202 while theextending wall 232 extends from the wall 204—as shown. In the embodimentshown, the outer end of the extending wall 232 extends beyond the outerend of the extending wall 230 by a first dimension of about 1¼ inches.As will be appreciated, the first dimension may be longer or shorter,but is preferably between about ½ inch to about 4 inches, and may beabout 1 inch or greater. Correspondingly, the tongue end 212 isstructured or configured to mate with the configuration of the grooveend 210—as shown in more detail in FIG. 4. The ends are complementary.As will be understood, in one embodiment, the end 210 configured withthe extending walls 230, 232 extends the entire length of the wallmember 200. Similarly, in one embodiment, the end 212 extends the entirelength of the wall member 200.

In another embodiment, one of the inner walls 206 a is spaced from theouter end of the extending wall 230 by a second dimension of about ¼inch. As will be appreciated, the second dimension may be longer orshorter, but is preferably between about ¼ inch to about 2 inches, andmay be about 1 inch or less.

The design and structure of panel wall member 200 enables assembly of awall structure with the groove end upward and tongue end downward—incontrast with how the prior art panel wall members 20 are assembled. Inaddition, the inventors have determined that this structure andconfiguration reduces or eliminates the need to caulk theinterconnection, unlike the prior art design.

The wall panel member 200 is similarly constructed (as the columns,beams, joists) and may be formed using a pultrusion process. The lengthof the panel 200 can be any desired length, and is chosen to spanbetween two or more columns of the structure 100, or as needed. In oneembodiment, each wall panel member 200 is a single, unitary piece, withlengths ranging from ten to sixty feet, and in one embodiment, is equalto or greater than the column spacing.

According to disclosed embodiments, the panel wall structure 648 may beassembled by interlocking a plurality of wall panel members 200. Forexample, a plurality of panels 200 may be interlocked to assemble theexterior wall structure 648 having a desired height and/or a desiredlength. Referring to FIGS. 5A and 5B, there are shown front and sideelevation views of the exterior wall structure 648 of the cooling tower600. As shown, the exterior wall 648 includes a plurality of wall panelmembers 200 interlocked and stacked on top of each other to form thewall.

It will be understood that the panel wall member 200 described herein isnot limited to use in cooling tower structures, but may be used in otherstructures or installations where it is desirable to contain water orother liquids on one side of the wall.

FIGS. 7A, 7B and 8A, 8B are detailed cross-sectional views withdimensional information of alternative wall panel members 200 b and 200c, respectively, in accordance with other embodiments. These Figuresillustrate, in other embodiments, each of the alternative wall panelmembers 200 b and 200 c having certain dimensions. Other dimensions arepossible.

As shown in FIGS. 7A and 7B, the inner wall 206 b of the groove end 210b is configured with a slot 700. Correspondingly, the tongue end 212 bis structured or configured to mate with the configuration of the grooveend 210 b, and further includes a smaller tongue portion 702 to matewith the slot 700—as shown in FIGUREs. The two ends are complementary.As will be understood, in one embodiment, the end 210 b configured withthe extending walls 230, 232 and the slot 700 structure extends theentire length of the wall member 200 b. Similarly, in one embodiment,the end 212 b configured with the tongue portion 702 extends the entirelength of the wall member 200 b. This tongue-and-groove configuration ishereinafter referred to as a “double tongue-and-groove structure” wherethe main tongue includes a secondary tongue, while the main grooveincludes a secondary groove. In other words, the tongue portion includesa main tongue portion and a secondary tongue portion, while the grooveportion includes a main groove portion and a secondary groove portion.

As shown in FIGS. 8A and 8B, the inner wall 206 c of the groove end 210b is configured with a smaller slot 800. Correspondingly, the tongue end212 c is structured or configured to mate with the configuration of thegroove end 210 c, and further includes an even smaller tongue portion802 to mate with the slot 800—as shown in the FIGUREs. The two ends arecomplementary. As will be understood, in one embodiment, the end 210 cconfigured with the extending walls 230, 232 and the slot 800 structureextends the entire length of the wall member 200 c. Similarly, in oneembodiment, the end 212 c configured with the tongue portion 802 extendsthe entire length of the wall member 200 c. This configuration isanother embodiment of the “double tongue-and-groove structure” where themain tongue includes a secondary tongue, while the main groove includesa secondary groove.

Though not shown in the figures, one or more mechanical means andstructures (other than adhesives or other chemicals) may be utilized tosecurely attach a first double wall panel to a second double wall panel.In other embodiments, no caulking is used in the interconnection jointbetween the two panels.

It may be advantageous to set forth definitions of certain words andphrases that may be used within this patent document: the terms“include” and “comprise,” as well as derivatives thereof, mean inclusionwithout limitation; the term “or,” is inclusive, meaning and/or; thephrases “associated with” and “associated therewith,” as well asderivatives thereof, may mean to include, be included within,interconnect with, contain, be contained within, connect to or with,couple to or with, be communicable with, cooperate with, interleave,juxtapose, be proximate to, be bound to or with, have, have a propertyof, or the like. The term “couple” or “connect” refers to any direct orindirect connection between two or more components, unless specificallynoted that a direct coupling or direct connection is present.

Although the present invention and its advantages have been described inthe foregoing detailed description and illustrated in the accompanyingdrawings, it will be understood by those skilled in the art that theinvention is not limited to the embodiment(s) disclosed but is capableof numerous rearrangements, substitutions and modifications withoutdeparting from the spirit and scope of the invention as defined by theappended claims.

What is claimed is:
 1. A panel wall member for use in a wall within acooling tower, the panel wall member comprising: a double wall panelmember having a first outer wall spaced laterally from a second outerwall, the first and second outer walls comprising fiber reinforcedmaterial; a first end having a tongue-type portion extending from thefirst and second outer walls and having a width narrower than a width ofthe double wall panel member; and a second end having a groove-typeportion and having a first groove wall portion extending from the firstouter wall and a second groove wall portion extending from the secondouter wall, the first groove wall portion extending further outward thanthe second groove wall portion.
 2. The panel wall member in accordancewith claim 1, wherein the first groove wall portion extends at leastabout one inch further outward than the second groove wall portion. 3.The panel wall member in accordance with claim 2, wherein the firstouter wall and the second outer wall are spaced apart between about ½inch to about 2 inches.
 4. The panel wall member in accordance withclaim 2, wherein the panel wall member is formed of pultruded compositeplastic material.
 5. The panel wall member in accordance with claim 1,further comprising: an inner wall member disposed proximate the secondend, the inner wall member spanning between and connected to the firstouter wall and the second outer wall; and wherein the inner wall memberis disposed at a location and configured to abut a surface of atongue-type portion of a second panel wall member.
 6. The panel wallmember in accordance with claim 5, wherein the second groove wallportion extends about 1 inch or less outward from the inner wall member.7. The panel wall member in accordance with claim 6, wherein the panelwall member has a length greater than 8 feet and a configuration of thefirst end and a configuration of the second end extend substantiallyalong the length of the panel wall member.
 8. The panel wall member inaccordance with claim 1, further comprising: at least three inner wallmembers spanning between and connected to the first outer wall and thesecond outer wall, the at least three inner wall members spaced apartfrom each other.
 9. The panel wall member in accordance with claim 1,wherein: the first end having the tongue-type portion comprises: a maintongue portion, and a secondary tongue portion; and the second endhaving the groove-type portion comprises: a main groove portion, and asecondary groove portion.
 10. A panel wall for use with a cooling tower,the panel wall: a first double wall panel member and a second doublewall panel member, wherein each double wall panel member comprises: afirst outer wall spaced laterally from a second outer wall, the firstand second outer walls comprising fiber reinforced material, a first endhaving a tongue-type portion extending from the first and second outerwalls and having a width narrower than a width of the double wall panelmember, and a second end having a groove-type portion and having a firstgroove wall portion extending from the first outer wall and a secondgroove wall portion extending from the second outer wall, the firstgroove wall portion extending further outward than the second groovewall portion; and wherein the first end and the second end of the firstdouble wall panel are interconnected to the second end and the firstend, respectively, of the second double wall panel.
 11. The panel wallin accordance with claim 10 wherein the second ends are oriented upwardand the first ends are oriented downward when the panel wall is attachedto a cooling tower.
 12. The panel wall in accordance with claim 10,wherein the first groove wall portion of the double wall panel memberextends at least about one inch further outward than the second groovewall portion.
 13. The panel wall in accordance with claim 10, wherein:each double wall panel member further comprises an inner wall memberdisposed proximate the second end, the inner wall member spanningbetween and connected to the first outer wall and the second outer wall;and the inner wall member is disposed at a location of each double wallpanel member and configured to abut a surface of the tongue-type portionof another double wall member.
 14. The panel wall in accordance withclaim 10, wherein the second groove wall portion extends about 1 inch orless outward from the inner wall member.
 15. The panel wall inaccordance with claim 14, wherein the panel wall member has a lengthgreater than 8 feet and a configuration of the first end and aconfiguration of the second end extend substantially along the length ofthe panel wall member.
 16. The panel wall in accordance with claim 11,wherein each double wall panel member further comprises: at least threeinner wall members spanning between and connected to the first outerwall and the second outer wall, the at least three inner wall membersspaced apart from each other.
 17. The panel wall in accordance withclaim 11, wherein: the first end having the tongue-type portion of eachdouble wall panel member further comprises: a main tongue portion, and asecondary tongue portion; and the second end having the groove-typeportion of each double wall panel member further comprises: a maingroove portion, and a secondary groove portion.
 18. A cooling towercomprising: a support frame structure defining an interior volume andhaving at least a first column and a second column; a fluid distributionsystem to distribute fluid within the interior volume defined by thesupport frame structure; a heat transfer material within the interiorvolume defined by the support frame structure and for receiving fluidfrom the fluid distribution system and through which the fluid travels;a fluid collection basin disposed beneath the support frame structure;air moving equipment operable for causing air movement for heat transferbetween the fluid and air; and an exterior panel wall coupled to andspanning between the first column and the second column, the exteriorpanel wall comprising, a first double wall panel member and a seconddouble wall panel member, wherein each double wall panel membercomprises: a first outer wall spaced laterally from a second outer wall,the first and second outer walls comprising fiber reinforced material; afirst end having a tongue-type portion extending from the first andsecond outer walls and having a width narrower than a width of thedouble wall panel member; and a second end having a groove-type portionand having a first groove wall portion extending from the first outerwall and a second groove wall portion extending from the second outerwall, the first groove wall portion extending further outward than thesecond groove wall portion, wherein the first end and the second end ofthe first double wall panel are interconnected to the second end and thefirst end, respectively, of the second double wall panel, and whereinthe second ends are oriented upward and the first ends are orienteddownward.
 19. The cooling tower in accordance with claim 18, wherein thefirst groove wall portion of each double wall panel member extends atleast about one inch further outward than the second groove wallportion.
 20. The cooling tower in accordance with claim 18, wherein:each double wall panel member further comprises an inner wall memberdisposed proximate the second end, the inner wall member spanningbetween and connected to the first outer wall and the second outer wall;and the inner wall member is disposed at a location of each double wallpanel member and configured to abut a surface of the tongue-type portionof another double wall member.